Method for fabricating human head replicas and the like having hair simulating filament embedded therein



1966 v; 1.. RODRIGUEZ. JR 3,

METHOD FOR FABRICATING HUMAN HEAD REPLICAS AND THE LIKE HAVING HAIR SIMULATING FILAMENT EMBEDDED THEREIN Filed Feb. 14, 1963 5 Sheets-Sheet 1 I N VE r-JTOR. V/A/czwr L. Poop/evade Aug. 9, 1966 V METHOD FOR FABRICPITING HUMAN HEAD REPLICAS AND TH HAVING HAIR SIM Filed Feb. 14, 1963 L. RODRIGUEZ. JR

[:I LIKE ULATING FILAMENT EMBEDDED THEREIN 3 Sheets-Sheet 2 9' 1966 v. L. RODRIGUEZ. JR 3,265,796

METHOD FOR FABRICATING HUMAN HEAD REPLICAS AND THE LIKE HAVING HAIR SIMULATING FILAMENT EMBEDDED THEREIN Filed Feb. 1.4, 1963 3 Sheets--Sheet 3 United States Patent Office 3,265,796 METHOD FOR FABRICATING HUMAN HEAD REPLICAS AND THE LIKE HAVING HAIR SIMULATING F I L A M E N T EMBEDDED THEREIN Vincent L. Rodriguez, Jr., 8928 Edda Villa Drive,

Rosemead, Calif. Filed Feb. 14, 1963, Ser. No. 258,575 3 Claims. (Cl. 264-421) The present invention encompasses the method of casting replicas of human features, which replicas realistically reproduce the hair of the person represented by the replica.

This invention provides simple and inexpensive articles, together with the methods of producing such articles, which incorporate accurate reproductions of the likeness of a specific human being. In a preferred embodiment of the invention, the article is cast from-a. hard setting plastic material which is colored to reproduce the flesh tones of the model. The invention also provides a method of embedding hair in a cast head so that the hair can be groomed to reproduce the hairstyle ofthe individual whose features are reproduced. A related invention disclosed herein is the method of making plastic-on-wood inlays of a decorative and novel nature.

In the past, when it was desired to reproduce human features in a three-dimensional form, either in a stylized representation or in the exact form of the features of a specific individual, the services of a skilled and talented sculptor was required to provide an original sculpture from which duplicates were produced. In a related field of endeavour, the production of life masks has required the services of skilled technicians to obtain the mold of the features of a living individual, from which mold the mask was cast. Regardless of the skill and artistic talent of such technicians, life masks have been limited in the degree to which they reproduce human features, particularly because the subjects eyes are closed during the making of the mold.

In either a life-mask or a sculpture hair is not reproduced realistically. Conventional life mask techniques usually require that a hard-setting semi fluid be poured over the features of the subject. The subjects hair must be covered with a membrane in order that the semi-fiuid material, such as quick-setting plaster, will not become embedded in the hair. Alternatively, the subjects face may be covered with grease to assure that plaster does not irritate the skin of the subject. In either of these techniques the reproduction of the features is not truly accurate. Additionally, the cost of providing life masks from which duplicates can be produced is expensive since a skilled sculptor is required to detail the mold or casting.

' By the method according to this invention, relatively unskilled persons can produce accurate and life-like reproductions of specific human heads, either as a bust or as a has-relief plaque mounted casting.

Generally speaking, the present invention further provides a method for casting a replica of the human head, the replica having hair simulating filaments embedded therein. The method comprises the steps of providing a primary mold defining a molding cavity having a casting surface configured to reproduce the head of the model. A selected part of the primary mold, corresponding to the hirsute scalp area of the head of the model, is then removed. A dissociable secondary mold part, correspond.- ing to the removed selected part of the primary mold, is then prepared. The secondary vmold part has a casting surface and filaments of hair simulating material are securely supported in the secondary part substantially independently of each other.

which project from the casting surface. The secondary The filaments have ends, a

mold part has a configuration conforming to the outline of the primary mold around the portion which was removed. The method also includes inserting the secondary m-old part into the primary mold to replace the removed selected part, the selected part being inserted so that the casting surface thereof is substantially aligned with the primary mold casting surface about the periphery of the secondary mold and so that the filaments extend into the cavity. A hard-setting material, having substantially no effect upon the integrity of the secondary mold, is then introduced into the cavity over the primary and secondary mold casting surfaces and over the exposed ends of the filaments. The material is set until it is hard and retains the filaments therein. The primary mold is then separated from the hard set material and the secondary mold part. The filaments external of the hard set material are then removed from the secondary mold part to provide the desired replica.

The above-mentioned and other features and objects of the invention are set forth in the following detailed description and explanation of the invention tal'en in conjunction with the accompanying drawings, wl erein:

FIG. 1 is an elevational view of a has-relief replica of a human head mounted on a plaque;

FIG. 2 is a cross-sectional view taken along line IIII of FIG. 1;

FIG. 3 is an idealized perspective view of a step in the process of making a replica according to the invention;

FIG. 4 is an idealized perspective view of another step in the method according to this invention;

FIG. 5 is a perspective view of yet another step in the method of this invention; and

FIG. 6 is a plan view of the assembled mold parts according to the method of this invention.

In a preferred embodiment of this invention the material from which inlay 50 is cast is an epoxy resin which has a low viscosity and which manifests a very low degree of shrinkage upon hardening. Epoxy resins very accurately reproduce the configuration of a mold into which they are cast. Pure epoxy resins may be soft upon hardening. It is therefore desirable that a hardening agent be added to the resin prior to the pouring of the inlay. A

number of chemical hardening agents for epoxy resins are known including polycarboxylic acids and their anhydrides, such as maleic, pyromellitic, phthalic, or hexahydrophthalic anhydride; polyamines or polyamides, such as ethylene diamine, diethylene triamine, piperidine, urea, dicyandiamine; and other agents including aromatic polysulfonic acids, di-isocyanates, and the like. A preferred hardening agent is a polyfunctional aliphatic amine such as diethylene triamine which reacts at room temperature to form a highly crossed link polymerized structure. A hardening agent from the class of polyfunctional aliphatic amines may be selected to provide any degree of hardness desired in the cast replica. Aromatic amines are also acceptable as hardening agents but are not preferred since they cure the resin very slowly at room temperature and result in brittle products which have low softening temperatures. (See Polymers and Resins, Golding, D. Van Nostrand Company, lnc. (1959).)

Epoxy resins of low molecular weight (low melting point) are preferred as casting materials in all the articles provided by this invention, but any plasti material which may be cast at a temperature such that wood is not charred may be used. It has been found that many liquid resins such as acrylics and unsatunated polyester resins have very desirable casting properties, but such resins either must be poured at high temperatures or generate high exothermic temperatures during the curing process in which the liquid resin sets into a solid. The temperatures associated with such resins are so high that wood is charred at these temperatures. Epoxy resins, on the Patented August 9, 1966 i other hand, may be poured at room temperature and therefore are preferred since there is no chance that the wood base of the replica will be charred by the heat of the liquid resin. Further, epoxy resins have excellent ad- =hcsive properties which are produced during the curing process. The replica is therefore bonded securely to its wood base and is maintained in place even when the base is subjected to flexure. Also, epoyy resins are preferred for practice with this invention since such resins may be tinted to any desirable color.

The formulation of the hardening agent with the epory resin is not set forth in detail in this description since practitioners in the plastic casting art recognize that such formulations are highly dependent upon the pot lifeof the resin and also upon the amount of resin which must be poured. It is desired, howeyer, that the formulation be such that the exothermic temperature developed as cross-linkages develop during the curing process be kept to a minimum. Too high an exothermic temperature may result in charting the wood to detract from the appearance of the completed article. Also, the plastic-towood bond is impaired when the wood is charred.

Referring to FIG. 1, a replica 50 of a human head is mounted to a plaque or plate 51 so that the replica may be hung on a wall. A medallion or engraved plate 52 is atfixed to the plaque to identify and describe the individual whose likeness is reproduced in replica 50, as when the replica is provided as a family memento or a historical monument. It should be noted, however, that while the replica illustrated in FIG. 1 is a has-relief reproduction of human features, this invention has utility in providing a bust of a human head. Only the bas-relief embodiment of the invention is presented here in detail since one skilled in the art can adapt the teachings of this invention to provide a bust-type reproduction.

It was mentioned above that in providing reproductions of human features, particularly the features of a specific individual (the specific individual hereinafter being referred to as the model or subject") that the services and talents of a skilled sculptor or a highly trained sculptural technician were required. This is one reason why life masks are not widely used as a vehicle for reproducing features of a person, either for historical or family memento purposes. Additionally, in casting life masks the hair of the individual is not faithfully reproduced since life masks conventionally are cast from plaster; protective coverings or coatings must be applied to the hair of the individual in order to prevent the hair from being embedded in a soft plaster of a mold in which the initial impression of the features of the individual are made. As illustrated in FIG. 1, the article produced according to the method of this invention provides a life-like reproduction of the features of a human and includes hair or a hair simulating material 53 which reproduces the hair color and style of an individual.

The characteristics of the replica produced by the method according to this invention will be set forth during the presentation of the method. It is mentioned at this point that the method has utility in areas other than in the reproduction of the features of a specific individual. For example, this invention may be used advantageously to provide life-like mannequins such as display mannequins used in the merchandising of wearing apparel, in which case the features of the mannequin may be stylized or impressionistic representations of the features of an imiginary person. Also, the invention finds application in the manufacture of dolls and other toys. It is noted that the foregoing illustrations of the areas of utility of this invention are no exhaustive and that additional areas of utility will be apparent to those skilled in the art.

The presentation of the method of making the replica 50 is made in conjunction with the manufacture of a basrelief reproduction of the features of a specific subject. The first step in providing a replica or reproduction of human features is to make an impression of the features of the subject in a body of semi-fluid material such as soft plaster. It is preferred that the plaster in which the impression is made he a quick-setting plaster in order that the face of the subject not be held in contact with the plaster for any longer a period than is necessary. Commercially available additives may be used to provide a plaster which sets" in approximately two minutes; such plaster quite adequately reproduces the contours of an article impressed against it. In making the impression, the hair of the subject is protected by a skull cap or hood which covers only the hirsute scalp area of the subject. The surface of the soft plaster is covered with a thin film of deformable material, such as a thin sheet of rubber or the transparent plastic film sold under the trademark Saran Wrap, against which subjects face is pressed. It have been found that the use of a large film prevents wrinkles in the film, which wrinkles are reproduced in the impression.

In describing this invention, the term semi-fluid material is used to distinguish from the term plastic which is used to refer to an organic compound such as an epoxy resin. A semi-fluid material is also referred to as a plastic material in that it is deformable to accommodate forces applied thereto. The term hirsute scalp area" refers to the hairbearing scalp area of a subject in which live hair follicles exist and is used to refer specifically to that area of the subjects head on which hair actually exists as distinguished from areas which may have become bald.

After the impression of the subjects features has been made according to the procedure described above, the semi-fluid material in which the impression was made is allowed to harden to provide a primary female mold 54 which defines a concave mold cavity having a mold or casting surface 55 which is configured to reproduce the facial features of the subject. In many cases it is necessary to partition the mold into several components, such as parts 56 and 57 shown in FIGS. 2 and 3, in order that the cast replica may be removed from the mold with ease. If the mold cavity is of such a configuration that partitioning is required, partitioning the mold comprises the second step in the method according to this invention.

The primary mold parts 56-and 57 are then assembled and casting surface 55 may be coated with an oil or light grease or with a synthetic release agent. The mold cavity is then partially filled with a material 59, such as liquid paraffin wax, which hardens to conform to the configurations of the casting surface of the primary mold. The paraffin wax should beof a type which is pliable at room temperatures. While the paraflin wax is still fluid, a core 60 (similar to core shown in FIG. 2) is inserted into the mold cavity so as to be spaced apart from primary mold parts 56 and 57 to displace .the liquid wax so that it fills the space between the core and the mold parts. It is preferred that the core be fabricated from plaster or plastic, but wood or any other material may be used. Also, it is preferred that the core be secured to a planar base 61, such as a sheet of plywood, when the replica is to assume the form of a has-relief as illustrated in FIG. 1. This technique may be used when a bust is to be cast in the primary mold. The wax covered core and its supporting base 61 are illustrated in a simplified form in FIG. 3 wherein the convolutions cast into the wax 20 are deleted to simplify the drawings. After the liquid material 59 between the core 60 and the mold parts 56 and 57 has set or hardened, the primary mold parts are removed from around the core. A preliminary casting 62 (see FIG. 3) comprises the base 61, the core 60 and the coating 59 of wax is then in condition for practice of subsequent steps of the method according to this invention. In the foregoing description and explanation of the method, the material 59 is referred to as parafiin wax. This is by way of example only and other substances which have the characteristics described may be usedwithin the scope of this invention.

r dike-mold. The locks of hair secured to the adhesive able. After the mold has been lined with waxand the.

wax has been worked into the details of the mold, plaster or plastic is then poured into the mold to provide the core.

The outline 63 of the hair-bearing or hirsute scalp area of the subject is then carefully determined and is traced;

into the soft surface of casting material 59 overmold core 60. The wax then is removed from the core within the area defined by the outline (see FIG. 4). After the core has been exposed in the hirsute scalp area, a sheetof adhesive coated material is laid on the core in the exposed area. it is preferred that strips of a material which has a an adhesive coating on both sides thereof be used to cover the exposed area of the core since the core has a generally spherical curvature.

Filaments 53 of hair or hair substitute are then laid against the exposed adhesive surface of the material which previously has been affixed to the exposed portions of the core. Locks of the hair are arranged on the adhesive ma terial in a manner corresponding to the manner in which the hair grows on the subject's head. The adhesive sheet, or the composite adhesive sheet comprised of a plurality of adhesive coated strips, is then removed from the core and laid flat. Since the core has a complex curvature it may be necessary to segment the sheet of adhesive material in order that it may be laid flat. Dike-like walls are then disposed around the edges of the segmented adhesive sheet to provide a mold. The moldwalls have a height corresponding to the thickness of wax layer 59 at the corresponding locations along outline 63 of the sub jects hirsute scalp area. it is preferred thatthin metal strips or strips of oiled kraft paper be used to provide the sheet are then carefully parted and a quantity of liquid material is poured over onto the adhesive sheet to the depth determined by the height of the dike-mold walls. The material which is poured onto the sheet in this step of the method preferably is awax material such as a paraffin wax like the paraffin wax referred to above, but any material which sets to a pliable and deformable state, and which is meltable on heating to a temperature of approximately 150-180 F. may be used. The wax is allowed to harden, after which the dike-mold walls are removed from around the edges of the adhesive sheet. At this point, the hair or hair simulating filaments 53 have ends 64 which are embedded in the sheet of pliable wax.

The wax coated adhesive strips, having the strands of hair or hair simulating material adhered thereto, then are replaced onto the exposed area of the core 60. As mentioned above, the wax is pliable at room temperature and therefore the adhesive sheets or strips may be conformed to the generally spherical curvature of the core. in replacing the adhesive strips upon the core, care should be taken to assure that the strips are replaced in exactly the same relationship, one-to-another, that they had prior to removal from the core. e

As illustrated inFlG. 5, a cylindrical weir.66is erected about the limits of the wax coated adhesive sheets which have been replaced upon core 60. The weir conforms to outline 63 of the hirsutescalp area and conforms exactly to the eonfiguratiofn "or the core It is preferred that.

weir 66 extend perpendicular to base 61 and that it allow for the hair or hair simulating material 53 to bis-disposed it is preferred that the weir loosely adjacent the core. define a closed loop when viewed from a direction perpcndicularto base 61.

A quantiy of slip materialis then poured into the weft.

and is allowed to set into a semi-fluid condition. The slip preferably is water soluble and is haltable. The slip may be common mud, but any soluble material which coagu-'.

' core runs off from the core, but this isdesired. Also, the

wax coating over the layer of adhesive material is melted and runs off from the adhesive sheet; this also is desired during the-baking process. After the slip has hardened, weir 66 is removed from around the hardened slip to expose the secondary female mold part. The mold part is soluble in a suitable solvent, preferably water, and has ends 64 of the hair or hair simulating material extending from a concave casting or mold surface 69. The exposed ends of the hair filament are lacquered to stiffen them for the final casting process.

Primary mold parts 56 and 57 are then cut away, as by the use of a high-speed bandsaw, to provide a recess 70 which conforms to the cylindrical configuration of sec ondary mold part 68. The secondary mold part is then inserted into recess 70, and is aligned relative to the primary mold parts such that casting surface 69 ofthe secondary mold part is aligned with casting surface 55 of the primary mold parts.

The method described to this point is compatible with the manufacture of 'a has-relief or bust-type replica. The

steps described subsequently may be omitted or modified in the manufacture of a bust-type replica. I

The plaque to which the replica 50 is to be secured is then prepared. Preferably plaque 51 has a surface 71 which is varnished or finished by other desirable means.

' A core or male moldpart 75 is secured to the plaque by sired material except plastic; the material from which the replica is cast may not adhere satisfactorily to a plastic core. Core 75 is disposed in a recess 77 provided in surface 71 of the surface of the plaque. The recess has a peripheral outline which conforms exactly to the outline v of the cavity defined in the assembled primary and secondary mold parts and may have vertical or undercut peripheral walls. The core is disposed so as to be spaced apart from the peripheral walls of recess 77. Core has dimensions which conform generally to the dimensions of the mold cavity but which are less than the corresponding dimensions of the mold cavity. 7

A plurality of casting holes or pipes 78 are drilled through the plaque into the area of the recess between the periphery of the core and the peripheral walls of the recess. It is preferred that pipe holes 78 be countersunk at their ends opposite from core 75 (as illustrated at 79 in FIG. 2). A false eye 80 is then secured to core 75 at a preselected location on the core corresponding to the location of the eye in the finished replica-The false eye is disposed in a recess 81 in thecore and is positioned so that it projects into the corresponding convolution of primary mold 54 when thecore isjnserted into the mold cavity. If desired, 7 the false eye may be secured to the mold at the preselected 'loca onw- The casting surfaces of the assembled primary and secondary mold partsare then coated with a thin film of a light oil-er. grease; A similar film of light oil or grease is then applied peripherally ofreeess 77' in plaque 51 to prevent flash in the casting process from adhering to the finished surface. The core and the plaque are then brought into engagement with the assembled mold parts 7 so that core is in a predetermined alignment with the lates 'or-hardens upon standing or. ,heating' mayher-used,

in the successful practice of the method for fabricating the I mold parts and-so that false eye 80 is directly opposite its corresponding location in the adjacent primary mold part...-It is also preferred that the false eye be coated 7 with lubricant so that the casting material does not-adhere thereto.

A casting material '84, preferably an epoxy resin, is then poured into the space between aligned core 75 and primary and secondary mold parts 56, 57,- 68 to fill this space completely. It is preferred that during the filling process the assembled-molds and plaque 51 be vibrated lightly to assure that air cavities do not appear in the casting material adjacent casting surfaces 55 and 69. The casting material is poured into the molds until it completely fills the casting pipes 78 and'appears in the countersunk areas 79 thereof. The casting material is then allowed to harden so as to securely embed exposed ends 64 of hair or hair simulating material 53 which extend from the soluble material of secondary mold part 68. The primary mold parts are then removed from the hardened casting. The removal of the primary mold parts from the casting and from the secondary mold part is facilitated because of the coating of the light oil or grease which was pmviously applied.

The material from which the secondary mold part 68 was fabricated is then dissolved to release the filaments of hair or hair simulated material. Any flash which appears on surface 71 of plaque 51 is then trimmed away from the finished casting. If any film of casting material covers the false eye, this also is trimmed away to expose the false eye. Any traces of lubricant which remain on the casting or on the plaque are dissolved with a suitable solvent. The replica is then finished by arranging and fixing the hair into the style in accord with the hair style of the subject. y

it is preferred that the material from which the casting is made he tinted to reproduce the flesh tones of the subject. it may be desirable, however, that the replica '50 be fabricated so as to provide an impressionistic interpretation of a human, in which case the casting material may be any color desired.

The replica described above has been fabricated from the following exemplary formulations of casting material applied and cured as set forth.

EXAMPLE 1 A liquid epoxy monomer, prepared in known manner from epichlorohydrin and diphenyloi propane, and having an epoxy equivalent weight of 200 and molecular weight of 400, essentially the same composition as a product of Shell Chemical Co., Division of Shell Oil Co.,

. New York, N.Y., known commercially as Epon #828,

was used to prepare a compound of the following formulation, the proportions being set forth on a weight basis:

Parts Epoxy resin 100 Ground limestone 50 Titanium dioxide 10 Yellow iron oxide 5 Cadmium red 0.5 Diethylene triamine 8 The epoxy resin and the pigments were milled together by conventional means and the diethylene triamine 'was thoroughly mixed with the resulting mixture. The fluid mixture was then degassed in a vacuum chamber and poured into a prepared mold. After curing at room tempcratune for 24 hours the casting was hard and capable of being removed from the mold. A satisfactory replica, as described above, was thus obtained.

EXAMPLE 2 8 Rutile titanium dioxide 5 Chrome yellow 1 Iron oxide red l Hexahydrophthalic anhydride 80 Benzyl dimethyl amine 1 The epoxy resin, hexahydrophthalic anhydride, and the benzyl'dimethyl amine were thoroughly blended at a EXAMPLE 3 Into'a resin kettle equipped with heating, cooling, vacuum, agitation, and a reflux condenser, was charged a mixture by weight, of the following materials in the given ratios:

Percent Diethylene glycol 28.5 Ethylene glycol 16.5 Phthalic anhydride 11.0 Maleic anhydride 33.5 Adipic acid 10.5

The agitator was turned on and the kettle was gradually heated at the rate of 10' C. per hour until a temperature of 200' C. was reached. After ohours the acid number of the formulation was 51. A vacuum of 100 millimeters of mercury was then applied and the kettle temperature was lowered to 180 C. After two hours the acid number of the liquid resin was 30. The temperature was then allowed to return to room ambient.

Styrene monomer was next added to the kettle in the ratio of 100 parts polyester resin to 40 parts of styrene,

and mixed until a clear solution was obtained. The viscosity of the liquid resin was 500 centipoises and the acid number was 25. Suitable pigments were then ground into the polyester resin so that a pinlrfleshlike color was obtained. To 100 parts of the pigmented polyester was added with good agitation, 0.5 parts of a 6% cobalt octoate solution, followed by the addition of 1.5 parts of methylethyl ketone peroxide.

The low viscosity mixture was then poured into a prepared mold in which simulated hair and an artificial eye had been inserted, and the separation surfaces coated with a hard wax followed by a sprayed coating of a polyvinyl alcohol solution to effect easy separation. The mold was that of a view of a human head prepared according to the foregoing description. After two hours at room temperature the resin was hard and the mold could be disassembled. The casting was cleaned of flash, separation agent, and extraneous stop-off material in the simulated hair." Upon examinations pleasing likeness of the original subject was found to have been obtained.

EXAMPLE 4 A decorative tsble'lamp wooden bare into which a complex recessed design had been cut was arranged so that the cavity was facing up. The surface of the wood cavity was coatedwlth a solution of cellulose acetate in nn organlcsolvent and allowed to dry. A damwas then built up around the cavity out of silicone putty and aluminum foil to that a reservoir was formed to hold the casting resin. The catalyzed and pigmented monomer was poured into a sealed glass bottle and placed 'in a water bath held at 120 F. for 3 hours, during which time partial polymerization had taken place and a viscous clear green syrup had formed. This syrup was then poured into the prepared cavity and covered with a sheet of thin polyethylene to prevent evaporation.

Enough casting resin was poured into the cavity to provide about 25% excess of the material actually re quired to fill the cavity. The filled mold was then left undisturbed for one week at room temperature, and then the dam and covering sheet were removed. The resin had hardened into a clear transparent glass-like material. Excess resin was mechanically removed by sanding, and the exposed wood surface and the resin fiush inlay were polished by conventional means. A beautiful jewel-like clear inlay was obtained. By repeating the process and using different colored dyes, and by providing a means for the light from the lamp to shine through the base inlays, a most unusual and decorative effect was obtained.

The above-described method may be varied by casting a replica which is recessed in the hirsute scalp area of the replica. For example, the portion of the replica within the hairline of the replica may be recessed below the surfaceofthe replica representing the exposed skin portions of the subject. Previously prepared sheets of hair-embedding material, having a thickness of M are then cut to the shape of the recess and are glued or bonded into the recess to provide the completed replica. The hair-embedding sheets may be fabricated from a flexible plastic. "lhe sheets may be prepared according to the method described in conjunction with the fabrication of the wax coated, hair-embedding adhesive strips.

While the invention has been described above in conjunction with specific apparatus and in specific applicatious, this has been by way of example only and is not to be considered as limiting the scope of this invention.

What is claimed is:

l. The method of casting a reproduction of the head of a human model and the like comprising the steps of (1) making an impression of the features of the model in a body of hard-setting semi-fluid material to pro vide a primary female mold part defining a molding cavity having a casting surface,

(2) removing a selected part of the primary female mold part which corresponds to the hirsute scalp area of the head of the model,

(3) preparing from a hard-setting soluble material a secondary female mold part corresponding to the .removed selected part of the primary female mold part, the secondary mold part having (a) a casting surface,

(b) filaments of hair simulating material embedded in the secondary mold part substantially independently of each other and having ends projecting from the casting surface, and

(c) a configuration conforming to the outline of the primary mold part around the portion thereof from which the selected part was removed,

(4) inserting the secondary mold part into the primary mold part from which the selected part was removed so that the casting surface of the secondary mold part is substantially aligned with the primary mold part casting surface peripherally of the secondary mold part and so that the filaments extend from the secondary mold part casting surface into the molding cavity,

(5) castlngthe reproduction by introducing a hardsetting casting material into theassembled primary and secondary mold parts, the castingmateriai be ing other than a solvent for the hard-setting soluble material,

(6) removing the cast reproduction and the secondary mold part from the primary mold part, and

i5 (7) dissolving the hard-setting material of the secondary mold .part from around said filament with a material which does not dissolve or alter the appearance of the casting material. 2. The-method of casting a rproduction of the head 10 of a human model and the like comprising the steps of v(1) making an impression of the features of the model into abody of quick-setting semi-fluid plaster to provide a primary female mold part defining a molding cavity having a casting surface,

(2) removing a selected part of the primary female mold part which corresponds to the hirsute scalp area of the head of the model,

(3) preparing from a hard-setting water soluble material a secondary female mold part corresponding to the removed selected part of the primary female mold part, the secondary mold part having (a) a casting surface,

(b) filaments .of hair simulating material embedded in the secondary mold part substantially independently of each other and having ends projecting from the casting surface, and

(c) a configuration of the mold surface conforming to the outline of the primary mold part around the portion thereof from which the selected part was removed,

(4) inserting the secondary mold part into the primary mold part from which the selected part was removed so that the casting surface of the secondary mold part is substantially aligned with the primary mold part casting surface peripherally of the secondary mold part and so that the filaments extend from the secondary mold part casting surface into the molding cavity,

(5) coating the casting surface of the primary mold part with a lubricant,

(6) casting the reproduction by introducing a water insoluble casting material into the assembled primary and secondary mold parts to embed the projecting ends of the filaments therein,

(7) removing the cast reproduction and the secondary mold part having the projecting ends of the hair simulating filaments from the primary mold part, and

(8) dissolving the hard-setting material of the secondary mold part from around said filaments.

. 3. The method of fabricating a replica of a human model and the like comprising the steps of (l) preparing'a primary mold defining a molding eavity therein having a casting surface configured to reproduce the head of the model,

(2) removing aselected part of the primary mold which corresponds to the hirsute scalp area of the head 'of the model,

(3) preparing a dissociable secondary mold part corresponding to theremoved selected part of the primary mold and having (a) a casting surface, 7 I

(b) filaments of-hair simulating material securely 'supported in the secondary mold part substantially'independently of each other and having ends projecting from the casting surface, and

(c) a configuration conforming to the outline of the primary mold around the portion thereof from which the selected part was removed,

(4) inserting the secondary meld part into the primary mold to replace the removed selected part so that the secondarymold part casting surface is sub- 1 1 1 2 stantially aligned with the primary mold casting sur- 339,334 4/1886 Searle 264222 face peripherally of the secondary mold part and 583,686 6/1897 Kitsee 264- so that the filaments extend from the secondary mo1d 803,004 10/ 1905 -Mayer 264-222 part casting surface into the molding cavity,- 99 ,7 3 7 1911 Mom; 264-222 (5) introducing a hard-setting material having 'sub- 5 1 337 47 2 1 1 5 stantially no effect upon the integrity f ,317,110 4 1943 pct-son 264-443 ondary mold part into the cavity to cover the cast- 2,932,042 5/1961 Gick 5 5 ing surfaces of the primary mold and the secondary 3 012 285 12/1961 Marcus ct 3L 264 76 mold part and the exposed ends of the filaments and 3'o21'565 2/1962 Bowman setting said material until it is hard and retains the filaments therein, FOREIGN PATENTS (6) separating the primary mold from the hard-set material and the secondary mold part, and 4/1960 Canada (7) removing the filaments external of the hard-set material from the secondary mold part to provide the 15 ROBERT WHITE Pmmry Emmmer' desired replica. JACOB STEINBERG, ALEXANDER H. BROD- MERKEL, Examiners. B. SNYDER, Assistant Examiner.

References Cited by the Examiner UNITED STATES PATENTS 156,679 11/1874 Sprngue -..16120 232,782 9/1880 Townsend 16l--20 

1. THE METHOD OF CASTING A REPRODUCTION OF THE HEAD OF A HUMAN MODEL AND THE LIKE COMPRISING THE STEPS OF (1) MAKING AN IMPRESSION OF THE FEATURES OF THE MODEL IN A BODY OF HARD-SETTING SEMI-FLUID MATERIAL TO PROVIDE A PRIMARY FEMALE MOLD PART DEFINING A MOLDING CAVITY HAVING A CASTINE SURFACE, (2) REMOVING A SELECTED PART OF THE PRIMARY FEMALE MOLD PART WHICH CORRESPONDS TO THE HIRSUTE SCALP AREA OF THE HEAD OF THE MODEL, (3) PREPARING FROM A HARD-SETTING SOLUBLE MATERIAL A SECONDARY FEMAL MOLD PART CORRESPONDING TO THE REMOVED SELECTED PART OF THE PRIMARY FEMALE MOLD PART, THE SECONDARY MOLD PART HAVING (A) A CASTING SURFACE, (E) FILAMENTS OF HAIR SIMULATING MATERIAL EMBEDDED IN THE SECONDARY MOLD PART SUBSTANTIALLY INDEPENDENTLY OF EACH OTHER AND HAVING ENDS PROJECTING FROM THE CASTING SURFACE, AND (C) A CONFIGURATION CONFORMING TO THE OUTLINE OF THE PRIMARY MOLD PART AROUND THE PORTION THEREOF FROM WHICH THE SELECTED PART WAS REMOVED, (4) INSERTING THE SECONDARY MOLD PART INTO THE PRIMARY MOLD PART FROM WHICH THE SELECTED PART WAS REMOVED SO THAT THE CASTING SURFACE OF THE SECONDARY MOLD PART IS SUBSTANTIALLY ALIGNED WITH THE PRIMARY MOLD PART CAST SURFACE PERIPHERALLY OF THE SECONDARY MOLD PART AND SO THAT THE FILAMENTS EXTEND FROM THE SECONDARY MOLD PART CASTING SURFACE INTO THE MOLDING CAVITY, (5) CASTING THE REPRODUCTION BY INTRODUCING A HARDSETTING CASTING MATERIAL INTO THE ASSEMBLED PRIMARY AND SECONDARY MOLD PARTS, THE CASTING MATERIAL BEING OTHER THAN A SOLVENT FOR THE HARD-SETTING SOLUBLE MATERIAL, (6) REMOVING THE CAST REPRODUCTION AND THE SECONDARY MOLD PART FROM THE PRIMARY MOLD PART, AND (7) DISSOLVING THE HARD-SETTING MATERIAL OF THE SECONDARY MOLD PART FROM AROUND SAID FILAMENT WITH A MATERIAL WHICH DOES NOT DISSOLVED OR ALTER THE APPEARANCE OF THE CASTING MATERIAL. 